随机须丛影像法纤维长度测量系统的光信号分析理论和基础算法研究

During the “Twelfth Five-Year Plan” period, hundreds of millions of Yuan was spend on importing fiber length measuring instruments, each set of which cost more than one million, and the domestic imitations of these instruments have a higher market share. The applicants have invented an innovative method for measuring the fiber length distribution based on transmission images of the random dual-beards, and any electromechanical device for arranging the fiber ends in sample is not needed in this method but demanded in the common instruments. The new method can reduce the cost and enhance the accuracy and functionality of the measurement. However, there are several issues which need to be solved to promote the practical application of this method. Firstly, the relative mass distribution was calculated from the transmission images of fiber beards by a new built optical model, which is based on the light scattering, reflection and absorption effects of the fiber assemblies. Secondly, the complete length distribution information of the fibers was extracted from the dual-beards, using a special hierarchical model to avoid the differential operation which will magnify the measurement errors. Thirdly, a pioneering parameter, the Floating Fiber Content in the drafting zone, will be predicted in quantity. This parameter is more applicable than the current length distribution curves and parameters, and can optimize the raw material matching and process design. Supported by this project, the new instrument will be developed in the near future, as an economical, rapid and accurate way for fiber length measurement.

“十二五”期间，我国进口纤维长度测试仪耗资数亿元，每套百万元以上，国产仿造仪器的市场份额更大。申请人发明了基于随机须丛透光图像测量纤维长度分布的全新方法，可省去现有仪器制作一端平齐须丛的机电装置，大幅度降低仪器成本，并具有更高精确度和功能，有望成为中国原创的更新换代仪器。本项目研究构建这类新测试系统亟需的纤维透光信号分析理论、长度分布曲线和新增功能纺纱浮游纤维预测的计算方法。国际首次全面考虑并妥善处理了纤维对光线的散射、反射、吸收作用，建立起纤维堆砌材料相对质量分布的光学计算模型。针对双端随机须丛特点提出逐步分离模型，避开放大“噪声”的微分运算求得完整准确的纤维长度分布。国际首次定量预测出所测纤维纺纱时的罗拉握持须丛线密度曲线和浮游纤维含量，可替代试纺优化原料设计和工艺设计，成为纺纱领域比现有测量结果更具应用价值的仪器新功能。本项目成果结合申请团队的原有基础，可迅速实施新测量系统产业化。

项目负责人发明了一种更新换代的纤维长度测试方法——随机须丛影像法，可具备成本低、精度高等优势。为研发使用该方法的新型仪器，本项目主要研究新测试法所需的光信号分析理论和基础算法：(1) 考虑光反射、散射和吸收的须丛质量分布计算方法；(2) 短绒率及长度分布曲线的新算法；(3) 纺纱罗拉握持纤维的须丛曲线和浮游纤维量的预测。.按计划完成了全部研究内容，主要研究论文30余篇，专著一本，会议报告1次，会议论文多篇；发明专利10项，期中7项已获授权；制定中英文国家标准一项；成果技术转移1项。.实现了全部预定研究目标：“本项目成果与申请团队原有研究成果组合，形成一套完善的纤维长度测量新理论和方法体系，包括制造原理、检测信号分析、长度特征曲线与指标计算方法，为我国自主知识产权的全新测量系统的产业化奠定理论基础”。.本项目不但完善了新测试方法的理论体系，而且超预期实现了成果应用：（1）采用本项目成果研制的羊毛长度测试仪被行业认可，正在制定中英文国家标准《毛型纤维长度测量法 随机须丛影像法》的任务, 标准号为20193338-T-424；（2）2020年5月中标获得中国纤维质量监测中心研制“分梳绒长度检测设备”项目（项目编号：20CNIC01-5108；经费66.8万元），有望替代现行国标GB18267-2013（山羊绒）中的手排长度测试法。本项目成果还可推动纺纱工艺和原料混配设计由经验型设计进步到定量的科学设计。